Integrated multi-element lubrication sensor and lubricant health assessment

ABSTRACT

A multi-element fluid sensor system having a distributed sensor configuration for determining the health state of a fluid. The sensor system includes at least two sensors for collecting data relating to a particular parameter (e.g., pH, temperature, electrical conductivity, chemistry, viscosity) of the fluid. The at least two sensors may be integrated onto a semiconductor base so as to provide for a micro sensor for in situ monitoring of the fluid. The system also includes a data fusion processor operatively coupled to the at least two sensors. The data fusion processor processes the fluid data to at least compensate for information fragmentation attributed to using the at least two sensors. The data fusion processor may condense the data, combine the data, evaluate the data and interpret the data.

RELATED APPLICATION(S)

This application is a continuation in part of U.S. patent applicationSer. No. 09/054,117, filed Apr. 2, 1998 now U.S. Pat. No. 6,023,961 andentitled MICRO-VISCOSITY SENSOR AND LUBRICATION ANALYSIS SYSTEMEMPLOYING THE SAME, the entirety of which is incorporated herein byreference.

TECHNICAL FIELD

The present invention generally relates to an integrated multi-elementlubrication sensor and health assessment system.

BACKGROUND OF THE INVENTION

Dynamoelectric machines such as motors and generators and other rotatingmachines such as gears and bearing systems are widely employed inindustrial and commercial facilities. These machines are relied upon tooperate with minimal attention and provide for long, reliable operation.Many facilities operate several hundred or even thousands of suchmachines concurrently, many of which are integrated into a largeinterdependent process or system. Like most machinery, at least a smallpercentage of such equipment is prone to failure. Some of such failurescan be attributed to loss of lubrication, incorrect lubrication,lubrication breakdown or lubrication contamination.

Depending on the application, the failure of a machine in service canpossibly lead to system or process down time, inconvenience, materialscrap, machinery damage, hazardous material cleanup and possibly even adangerous situation. Thus, it is desirable to diagnose the machinery forpossible failure or faults early in order to take preventive action andavoid such problems. Absent special monitoring for certain lubricationproblems, the problem may have an insidious effect in that although onlya minor problem on the onset, the problem could become serious if notdetected. For example, bearing problems due to inadequate lubrication,lubrication contamination or other causes may not become apparent untilsignificant damage has occurred.

Proper lubrication facilitates the extension of machinery life. Forexample, when motor lubricant is continuously exposed to hightemperatures, high speeds, stress or loads, and an oxidizingenvironment, the lubricant will deteriorate and lose its lubricatingeffectiveness. The loss of lubricating effectiveness will affect twomain functions of a lubrication system, namely: (1) to reduce friction;and (2) to remove heat. Continued operation of such a degraded systemmay result in even greater heat generation and accelerated systemdegradation eventually leading to substantial machinery damage andultimately catastrophic failure. To protect the motor, the lubricantshould be changed in a timely fashion. However, a balance must bestruck—on one hand it is undesirable to replace an adequate lubricantbut on the other hand it is desired to replace a lubricant that is inits initial stages of breakdown or contamination before equipment damageoccurs. Since each particular application of a lubricant is relativelyunique with respect to when the lubricant will breakdown or possiblybecome contaminated, it becomes necessary to monitor the lubricant.

Various techniques for analyzing lubricants are known. For example,measuring a dielectric constant change in the lubricant or recording athermal history of the lubricant have been employed for monitoring thelubricant's condition. However, these methods measure a single parameterand require the use of the same lubricant or assume no machinerymalfunctions throughout the measurements. Furthermore, these monitoringtechniques are generally not performed in situ and typically requirethat a sample of the lubricant be extracted and analyzed usinglaboratory grade equipment to determine the condition of the lubricant.The need to monitor and determine the current and future health oflubricants include grease and oils such as used in bearing systems formotors, gears, pillow blocks, hydrodynamic bearings as well as hydraulicfluids such as found in pumps and pump systems, and cutting fluids toname a few.

Single parameter sensors only provide a narrow view of a lubricantquality and/or health. Accurate lubricant health assessment and lifetimeprediction is virtually impossible to achieve via sensing a singleparameter of the lubricant. The need for more information about thelubricant is readily apparent from the many parameters which arereported in a typical laboratory report of lubricant condition.

In view of the above, there is a need for an improved sensor fordetecting an operating state of a lubricant.

SUMMARY OF THE INVENTION

The present invention relates to a microfabricated integratedelectrochemical and viscosity sensor. In particular, the presentinvention relates to an integrated multi-element lubrication sensor andhealth assessment system. The lubrication sensor is made usingintegrated circuit-like microfabrication techniques (e.g., silicon basedfabrication and deposition techniques). As a result, the lubricationsensor of the present invention provides for substantial advantages interms of performance, reduced size, weight and costs—especially sincethe wafer level technology employed affords for automated and batchproduction of numerous lubrication sensors on a single wafer. As will bedescribed in greater detail in the foregoing discussion, the presentinvention also provides for integrated signal processing and sensorfusion as well as communications.

The lubrication sensor includes multiple elements (e.g., sensingdevices) for sensing various characteristics of a lubricant. Forexample, the lubrication sensor includes a pH sensor, an electrochemicalsensor, a conductivity sensor, viscosity sensor and temperature sensor.The reduced size of the lubrication sensor of the present inventionprovides for continuous in situ monitoring of the lubricant. In otherwords, the lubrication sensor of the present invention affords formonitoring the lubricant within its operating environment as compared toextracting a sample and testing the lubricant at a remote site. Signaldata from each of the sensing devices is combined within a data fusionframework to obtain useful information relating to the condition of thelubricant as well as the machine and/or process employing the lubricant.

The present invention employs data fusion because of information fissionwhich is inherent to a process relating to sensing a physicalenvironment through several different sensor modalities. In particular,each sensing element provides a unique window into the physicalenvironment where the phenomena to be observed is occurring. Because thecomplete details of the phenomena being studied (e.g., detecting theoperating state of the lubricant or the process) are not containedwithin a single sensing element window, there is informationfragmentation which results from this fission process. These informationfragments associated with the various sensing devices contain bothindependent and dependent components. The independent components areused to further fill out (or span) the information space and thedependent components are employed in combination to improve the qualityof common information recognizing that all sensor data is subject toerror and noise. In this context, data fusion is algorithmic processingof sensor data to compensate for the inherent fragmentation ofinformation because a particular phenomena may not be observed directlyusing a single sensing element. In other words, the data fusionarchitecture provides a suitable framework to facilitate condensing,combining, evaluating and interpreting the available sensed informationin the context of the particular application.

Thus, the present invention provides for a micro multi-elementlubrication sensor which affords in situ monitoring of a plurality oflubricant parameters. Furthermore, the present invention employs a datafusion framework and algorithms to facilitate condensing, combining,evaluating and interpreting various sensed data. The present inventionalso facilitates establishing a health state of a system employing thelubrication sensor of the present invention, as well as predicting afuture state of the lubricant and/or system employing the lubricationsensor. Additionally, the lubrication sensor may communicate raw data,diagnostic data and state data to a remote device.

In accordance with one aspect of the present invention, a multi-elementfluid sensor system includes: at least two sensors, each sensor adaptedto collect data relating to a fluid; and a data fusion processoroperatively coupled to the at least two sensors, the data fusionprocessor processing the fluid data to at least compensate forfragmentation of information attributed to using the at least twosensors.

Another aspect of the present invention relates to a fluid sensingsystem including: at least two sensors integrated onto a semiconductorbase, the sensors respectively collecting data relating to a fluid; anda data fusion processor also integrated onto the semiconductor base andbeing operatively coupled to the at least two sensors, the data fusionprocessor processing the fluid data to at least compensate forfragmentation of the fluid data attributed to using the at least twosensors.

Yet another aspect of the present invention relates to a system for insitu monitoring of a lubricant employed in a dynamoelectric machine,including: means for collecting data for a plurality of parametersrelating to the health of the lubricant; and means for fusing the datato at least compensate for fragmentation of information between the datafor the plurality of parameters.

Still another aspect of the present invention relates to a method for insitu monitoring of a lubricant, including the steps of: using at leasttwo sensors to collect data relating to the health state of thelubricant while the lubricant is being used; and using a data fusionsystem to process the data.

Another aspect of the present invention relates to a lubrication sensorincluding: at least two sensors, each sensor adapted to collect datarelating to a lubricant; and a data fusion processor operatively coupledto the at least two sensors, the data fusion processor processing thelubricant data to at least compensate for fragmentation and/or overlapof information attributed to using the at least two sensors.

Still yet another aspect of the present invention relates to alubrication sensor for use in connection with a dynamoelectric machine,including: at least two of the following sensing devices adapted tocollect data relating to a lubricant: a temperature sensor for sensingtemperature of the lubricant, a viscosity sensor for sensing viscosityof the lubricant, a chemical sensor for sensing chemical parameters ofthe lubricant, a conductivity sensor for sensing conductivity of thelubricant, a pressure sensor for sensing lubricant pressure; a fluiddensity sensor for sensing lubricant density; and a pH sensor forsensing lubricant pH; and a data fusion processor operatively coupled tothe at least two sensing devices, the data fusion processor processingthe lubricant data to at least compensate for fragmentation and/oroverlap of information attributed to using the at least two sensingdevices.

Another aspect of the present invention relates to a multi-element fluidsensor system, including a first sensor adapted to collect data relatingto a fluid; a second sensor substantially identical to the first sensor,the second sensor providing redundancy in collecting the fluid data; anda processor operatively coupled to the first and second sensors, thedata fusion processor processing the fluid data; wherein the employmentof the second sensor facilitates fluid data reliability and accuracy.

To the accomplishment of the foregoing and related ends, the invention,then, comprises the features hereinafter fully described andparticularly pointed out in the claims. The following description andthe annexed drawings set forth in detail certain illustrativeembodiments of the invention. These embodiments are indicative, however,of but a few of the various ways in which the principles of theinvention may be employed. Other objects, advantages and novel featuresof the invention will become apparent from the following detaileddescription of the invention when considered in conjunction with thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective illustration of a lubrication sensor inaccordance with one embodiment of the present invention;

FIG. 2 is a functional schematic diagram of an integrated AC inductionmotor and lubrication analyzer employing the lubrication sensor of FIG.1 in accordance with the present invention;

FIG. 3 is a block diagram of a lubrication sensor and lubricationanalyzer in accordance with one embodiment of the present invention;

FIG. 4a is a function block diagram illustrating a data fusion processin accordance with one embodiment of the present invention;

FIG. 4b is a flow diagram illustrating an algorithm for determiningoptimal decision rules in accordance with the present invention;

FIG. 4c is a block diagram illustrating the employment of a neuralnetwork in deriving a parameter relating to lubricant operating state;

FIG. 4d is a block diagram of a plurality of sensing devices operativelycoupled to a data fusion processor in accordance with the presentinvention;

FIG. 4e is a block diagram of a lubrication analyzer including aplurality of sensing devices and a data fusion processor on a singlesemiconductor base in accordance with the present invention;

FIG. 5a is a perspective illustration of a lubrication sensor inaccordance with another embodiment of the present invention;

FIG. 5b is a perspective illustration of a lubrication sensor inaccordance with yet another embodiment of the present invention;

FIG. 6a is a functional schematic diagram of a motor bearing lubricationdiagnostic system in accordance with one embodiment of the presentinvention;

FIG. 6b is a functional schematic diagram of a motor bearing lubricationdiagnostic system in accordance with another embodiment of the presentinvention;

FIG. 6c is a functional schematic diagram of a lubrication diagnosticsystem for diagnosing lubrication regarding a plurality of machines inaccordance with another embodiment of the present invention;

FIG. 7a is a schematic block diagram of a lubrication sensor sensingdevice being employed in connection with a gear box in accordance withthe present invention;

FIG. 7b is a schematic block diagram of a lubrication sensor sensingdevice being employed in connection with bearings for a pillow block inaccordance with the present invention;

FIG. 7c is a schematic block diagram of a fluid sensing device beingemployed in connection with a hydrodynamic bearing in accordance withthe present invention;

FIG. 7d is a schematic block diagram of a hydraulic fluid sensing devicebeing employed in connection with a hydraulic pump and motor inaccordance with the present invention;

FIG. 7e is a schematic block diagram of a plurality of lubricationsensing being employed in connection with a motor bearing in accordancewith the present invention;

FIG. 7f is a schematic block diagram of a set of lubrication sensorsbeing employed in connection with a machinery lubrication system inaccordance with the present invention;

FIG. 8 is a perspective illustration of a silicon substrate undergoingdeposition, photolithography and etching steps in accordance with thepresent invention;

FIG. 9 is a perspective illustration of the silicon substrate of FIG. 8after formation of a pH electrode in accordance with the presentinvention;

FIG. 10 is a perspective illustration of the substrate of FIG. 9 beingmasked, etched and patterned to form a pH reference electrode andchemical sensor in accordance with one embodiment of the presentinvention;

FIG. 11 is a perspective illustration of the substrate of FIG. 10 afterformation of the pH reference electrode and electro-chemical sensor inaccordance with the present invention;

FIG. 12 is a perspective illustration of the substrate of FIG. 11 beingmasked, etched and patterned to form platinum contacts and a temperaturesensor in accordance with the present invention;

FIG. 13 is a perspective illustration of the substrate of FIG. 12 afterformation of the platinum contacts and a temperature sensor inaccordance with the present invention;

FIG. 14 is a perspective illustration of the substrate of FIG. 13 beingmasked, etched and patterned to form silver reference electrodes for apH sensor and electrical conductivity sensor in accordance with thepresent invention; and

FIG. 15 is a perspective illustration of a substantially completelubrication sensor in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with reference to thedrawings, wherein like reference numerals are used to refer to likeelements throughout.

As is mentioned above, the present invention relates to a microelectromechanical system type (MEMS-type) multi-element lubricationsensor and health assessment system. The present invention affords forin situ monitoring of a variety of fluid parameters via a plurality ofsensing devices (elements). A data fusion framework is employed tofacilitate condensing, combining, evaluating and interpreting thevarious sensed data.

Referring initially to FIG. 1 an exemplary multi-element lubricationsensor 20 in accordance with the present invention is shown inperspective view. Although the discussion herein is primarily directedto lubrication sensing, it is to be appreciated that the presentinvention has applicability to a variety of fluids as well such as forexample hydraulic fluids, cutting fluids and biological fluids. All suchsuitable applications are intended to fall within the scope of thehereto appended claims.

The lubrication sensor 20 includes a semiconductor base 24 whichpreferably comprises silicon, however, any suitable material may beemployed. Located on the surface of the base 24 are a plurality ofsensing devices 26 for sensing various parameters of a lubricant. Moreparticularly, the sensing devices 26 include a pH sensor 30 for sensingthe pH of the lubricant. A chemical sensor 36 provides for sensing thechemistry of the lubricant. A conductivity sensor 40 provides forsensing the electrical conductivity of the lubricant. A temperaturesensor 44 provides for sensing the temperature of the lubricant.

The pH sensor 30 includes a reference electrode 50 comprising anysuitable material (e.g., Ag, AgCl) and a pH electrode 52 comprising any,suitable material (e.g., palladium-palladium oxide (Pd-PdO)). The pHsensor 30 provides for sensing the pH of the lubricant or fluid beinganalyzed. An exemplary discussion relating to pH sensors is found in “APd-PdO Film Potentiometric pH Sensor, by Karagounis et al., IEEETransactions on Biomedical Engineering, Vol. BME-33, No. 2, February1986 which is hereby incorporated by reference in its entirety.

The chemical sensor 36 is of a 3-electrode configuration which includesa reference electrode 54 comprising any suitable material (e.g., Ag,AgCl), a working electrode 56 (e.g. comprising Ag) and a counterelectrode 58 (e.g., comprising Ag). The chemical sensor 36 is of adesign typically used in conjunction with voltammetric techniques. It isto be appreciated that other suitable sensor designs including a2-electrode electrochemical sensor, may be employed. When either an ACor DC voltammetric signal is applied to the working electrode 56, aresponse current is generated between the working electrode 56 and thecounter electrode 58. The response current signal parameters varydepending upon the electrochemical processes occurring at the surface ofthe working electrode 56. The electrochemical processes are a functionof the constituent concentrations, and the response current is thereforeresponsive to these concentrations. The electrochemical sensor is usefulfor determining the presence of contaminants like water or oxidation,for example, in the lubricant being analyzed.

The electrical conductivity sensor 40 is of a two electrode design,however, it is to be appreciated that other configurations (e.g., fourelectrode) may be employed. In the preferred embodiment, the twoelectrodes (40 a, 40 b) comprise gold, however, any suitable metal ormaterial may be employed. Two and four electrode conductivity sensorsare well known and thus further discussion related thereto is omittedfor sake of brevity. Knowledge of the conductivity is also useful fordetermining if metal wear and/or water is contaminating the lubricant,for example.

The temperature sensor 44 provides for determining the temperature ofthe lubricant or fluid being analyzed, and is preferably formed fromplatinum, however, it is to be appreciated that any material (e.g.,gold) suitable for carrying out the present invention may be employed.The temperature sensor 44 is patterned on the base 24 in accordance witha predetermined length, width and surface area. Therefore, by knowingthe surface area of the temperature detector 44 and the material ofwhich it is made, a temperature of a lubricant to which the temperaturesensor 44 is exposed may be determined based on the electricalconductivity of the temperature detector 44. Knowledge of the lubricanttemperature is useful in interpreting the health state of the lubricantbeing analyzed because certain lubricant parameters (e.g. viscosity) area function of lubricant temperature. Furthermore, the rate oflubrication breakdown or additive depletion is also a function oftemperature. Therefore, predicting the remaining useful life of thelubricant also requires temperature measurement.

Each lubricant parameter sensor (e.g. pH sensor 30, electrochemicalsensor 36, conductivity sensor 40, temperature sensor 44) has respectivesets of contact pads 60 a-60 i (collectively referred to by referencenumber “60”) which provide for easy coupling to the respective sensors.The lubricant sensor 20 is small having a square area of approximately 4mm. Accordingly, the lubrication sensor 20 is desirable for use inapplications where space is at a premium but where accuracy,reliability, and sensitivity of measured data are also at a premium.Furthermore, because the lubrication sensor 20 is fabricated inaccordance with integrated circuit-like fabrication techniques, largebatches of the lubrication sensors 20 may be easily and efficientlyproduced with good production yields, using conventional waferfabrication facilities.

It is to be appreciated that another set of sensing devices 26 andelectrical contacts 60 may be formed on the other side of the base 24 soas to increase the functionality of the lubrication sensor 20.

Furthermore, it is to be understood that some sensing devices 26 may beomitted from the lubrication sensor 20 and/or different types of sensingdevices (e.g., pressure sensor, IR sensor, light sensor, density sensor,light transmission sensor, shear sensor) may be incorporated into thelubrication sensor 20. One, some or all of the sensing devices 26 may bereplicated “n” number of times (wherein “n” is an integer) on a singlelubrication sensor 20. Such an embodiment may provide for increasedreliability because if one particular sensing device failed there wouldbe like sensing devices serving as backups. Multiple sensing devices ofthe same type on a single lubrication sensor may also afford forincreased accuracy as a result of improved signal to noise ratio. Themultiple versions of the same sensing element type may span a wide rangeof sizes, ratios, etc., each of which has a range of optimal sensingaccuracy. Together these sensor elements 26 provide for substantialaccuracy over a wide range of parameter values. The replicated sensingdevices 26 may also improve dynamic range of the lubrication sensor 20as well as versatility (e.g., the lubrication sensor may be employed ona wide range of materials and/or fluids). Such an embodiment may alsohave enhanced integrity because it may be able to sense if a particularsensing device 26 has failed or to identify the type of contaminant(e.g., engine coolant, transmission fluid).

Turning now to FIG. 2, an exemplary environment in which the presentinvention may be employed is shown. A three-phase AC induction motor 70is depicted driving a load 72 through a shaft coupling 74. The motor 70includes a junction box 76 for receiving conductors from power lines viaa conduit 78, which are tied to power supply lines (not shown) of themotor 70. The motor 70 is AC powered and operates at an AC power linefrequency of 60 Hz. However, it is appreciated that different linefrequencies (e.g., 50 Hz) may be employed. Coupled to the motor 70 is alubrication analyzer 90 (FIG. 3) which as will be discussed in greaterdetail below provides for receiving and processing data relating to thehealth of lubricant employed by the motor 70.

The lubrication analyzer 90 includes a display 92 for displaying to anoperator information relating to the health of the lubricant. It is tobe appreciated that the lubrication analyzer 90 may also perform otherfunctions relating to determining the health of the motor 70 (e.g.,current signature analysis, vibration analysis, etc.). The lubricationanalyzer 90 further includes an operator input device 98 in the form ofa key pad which enables a user to enter data, information, functioncommands, etc. as is conventional. For example, the user may inputinformation relating to lubricant type via the keypad 98 for subsequenttransmission to a host computer 102. In addition, the keypad 98 mayinclude up and down cursor keys for controlling a cursor which may beshown on the display 92. The lubrication analyzer 90 includes acommunications port 106 for interfacing the lubrication analyzer 90 withthe lubrication sensor 20 (FIG. 3) and the host computer 102 via asuitable communications link.

According to an embodiment of the present invention, the lubricationanalyzer 90 is part of a distributed communication system including anetwork backbone 120. The network backbone 120 may be a hardwired datacommunication path made of twisted pair cable, shielded coaxial cable orfiber optic cable, for example, or may be wireless or partially wirelessin nature. Information is transmitted via the network backbone 120between the host computer 102 and the lubrication analyzer 90. Thecommunication link preferably adheres to the RS232C or DeviceNetstandard for communicating command and parameter information. However,any communication link suitable for carrying out the present inventionmay be employed.

Referring now in particular to FIG. 3, a schematic representation of thepresent invention is shown according to one particular aspect of thepresent invention, wherein the lubrication analyzer 90 is integratedwith the lubrication sensor 20. However, it will be appreciated from thediscussion herein that the lubrication analyzer 90 may be locatedremotely from the motor 70. Furthermore, it is to be appreciated thatthe host computer may serve to carry out substantially all of thefunctions described herein performed by the lubrication analyzer 90. Itis also to be appreciated that in accordance with another specificaspect of the present invention, the lubrication analyzer 90 (absentcertain components) may be integrated onto a semiconductor chip with thelubrication sensor 20. In accordance with another specific embodiment,the lubrication analyzer 90 may be completely integrated within themotor 70 (e.g., in an intelligent motor), a gear box, or a bearing, forexample.

In the preferred embodiment, the lubrication analyzer 90 includes ahousing which is suitably shielded to protect the lubrication analyzer90 from whatever environment (e.g., dust, moisture, heat, vibration,lubrication) the motor 70 is working in. Additionally, the interior ofthe lubrication analyzer 90 may be suitably insulated with thermalinsulation between the motor and the lubrication analyzer so as toprotect it from heat generated by the motor 70.

The lubrication sensor 20 includes the pH sensor 30, the chemical sensor36, the conductivity sensor 40 and the temperature sensor 44. Each ofthe sensors 26 is operatively coupled to a processor 130 of thelubrication analyzer 90 via respective analog to digital (A/D)converters 136 which convert the analog signals output from the sensors26 to digital form for processing by the processor 130.

The temperature detector 44 varies in electrical conductivity dependingon the temperature of the lubricant. Accordingly, the temperature of thelubricant can be determined from the output of a voltage sensor 134which is coupled to the temperature detector 44 because the outputvoltage will vary in correspondence with the lubricant temperature. Thefollowing table illustrates the analytic relationship between lubricantviscosity and lubricant temperature, which can be monitored via theconductivity of the temperature detector 44.

GOOD CONDUCTIVITY OF LUBRICANT LUBRICANT TEMP. DETECTOR 40 TEMPERATUREVISCOSITY V₁ T₁ LV₁ V₂ T₂ LV₂ V₃ T₃ LV₃ . . . . . . . . . V_(N) T_(N)LV_(N)

A more detailed discussion relating to the analytic relationship betweenlubricant viscosity and lubricant temperature is presented in co-pendingU.S. patent application Ser. No. 09/054,117, entitled MICRO-VISCOSITYSENSOR AND LUBRICATION ANALYSIS SYSTEM EMPLOYING THE SAME, which ishereby incorporated by reference in its entirety.

The lubrication sensor 20 may be tailored to output measurements in anysuitable format in accordance with the present invention. For example,the output signals may be provided as digital serial; digital parallel;or current (4-20 mA).

The processor 130 is responsible for controlling the general operationof the lubrication analyzer 90. The processor 130 is programmed tocontrol and to operate the various components of the lubricationanalyzer 90 in order to carry out the various functions describedherein. The processor or CPU 130 can be any of a plurality of suitableprocessors, such as the p24T, Pentium 50/75, Pentium 60/90, and Pentium66/100, Pentium PRO and Pentium 2, and other similar and compatibleprocessors. The manner in which the processor 130 can be programmed tocarry out the functions relating to the present invention will bereadily apparent to those having ordinary skill in the art based on thedescription provided herein and thus further discussion related theretois omitted for sake of brevity.

A memory 164 operatively coupled to the processor 130 is also includedin the lubricant analyzer 90 and serves to store program code executedby the processor 130 for carrying out operating functions of thelubricant analyzer 90 as described herein. The memory 164 also serves asa storage medium for storing information such as nominal lubricanttemperature, pH, electrochemistry, viscosity data, etc. The memory 164may also include machine specific data and acceptable errorbounds/deviation values which may be used to facilitate determining thesuitability of the lubricant being analyzed. Furthermore, the memory 164may be used to store current and historical lubricant or fluid parameterdata, and corrective action which may be recommended. The data may betransmitted to a central processor and/or employed to perform time-basedtrending and analysis to determine lubricant or fluid health and futurehealth and desirable re-lubrication interval.

The memory 164 includes read only memory (ROM) and random access memory(RAM). The ROM contains among other code the Basic Input-Output System(BIOS) which controls the basic hardware operations of the lubricationanalyzer 90. The RAM is the main memory into which the operating systemand application programs are loaded. The memory 164 is adapted to storea complete set of the information to be displayed. According to apreferred embodiment, the memory 164 has sufficient capacity to storemultiple sets of information, and the processor 130 could include aprogram for alternating or cycling between various sets of displayinformation. This feature enables the display 92 to show a variety ofeffects conducive for quickly conveying lubricant state information to auser.

Power is provided to the processor 130 and other components forming thelubricant analyzer 90 from a power supply 170.

The lubricant analyzer 90 includes a data communication system whichincludes a data communication port 106 and communications card (notshown), which is employed to interface the processor 130 with the hostcomputer 102 via the network 120 (FIG. 2). The communication linkpreferably adheres to the RS232C or DeviceNet standard for communicatingcommand and parameter information. However, any communication linksuitable for carrying out the present invention may be employed.

It should be appreciated that the present invention may be used in asystem which does not include the host computer 102. All processingincluding data analyses and lubricant or fluid state estimation andhealth determination could be accomplished by the processor 130 and theresults transmitted to a PC or a control computer such as a programmablelogic controller (PLC) (not shown) or only displayed locally on thelubricant analyzer display screen 92. Furthermore, only one data linkmay be required. According to another embodiment, the processor 130could be employed to simply trigger a single bit, digital output whichmay be used to open a relay and turn the motor 70 off or signal analarm.

The display 92 is coupled to the processor 130 via a display drivercircuit 180 as is conventional. The display 92 may be a liquid crystaldisplay (LCD) or the like. In the preferred embodiment, the display 92is a fine pitch liquid crystal display operated as a standard CGAdisplay. The display 92 functions to display data or other informationrelating to the state of the lubricant and if desired the state of themotor 70 and recommend action (e.g. change lube in 2 weeks). Forexample, the display 92 may display a set of discrete lubricant or fluidcondition indicia such as, for example, temperature, pH,electrochemistry, viscosity, and normal operation indicia which isdisplayed to the operator and may be transmitted over the network 120.The display 92 is capable of displaying both alphanumeric and graphicalcharacters.

Alternatively, the display 92 may comprise one or more light emittingdiodes (LEDs) (e.g., a tri-state LED displaying green, yellow or redcolors depending on the health state of the lubricant).

The lubrication analyzer 90 may also include its own RF section 190connected to the processor 130. The RF section 190 includes an RFreceiver 192 which receives RF transmissions from the host computer 102for example via an antenna 194 and demodulates the signal to obtaindigital information modulated therein. The RF section 190 also includesan RF transmitter 196 for transmitting information via a wireless linkto the host computer 102 for example in response to an operator input.This wireless link may eliminate the cost, noise problems and otherproblems related with the wireline link 120.

The lubrication analyzer 90 includes a voltage driver 197 which isoperatively coupled to the processor 130 and the lubrication sensor 20.The voltage driver 197 provides a series of desired voltage to thelubrication sensor 20 in order to drive certain sensing devices (e.g.,chemical sensor 36).

The lubricant analyzer 90 may also include an adaptive processor 198such as for example a neural network and/or an expert system tofacilitate analyzing the health state of the lubricant. Alternatively,the adaptive processor 198 may be located in the host computer 102 ifdesired.

The programming or training of neural networks involves supplying theinput and corresponding output data of samples containing features,similar to those being searched for. The neural network in turn learnsby adjusting weights assigned to each of the neurons. The weights andthreshold values of neurons of the neural network determine thepropagation of data through the network and thus provides a desiredoutput based on a respective set of inputs.

Expert systems are knowledge-based systems which are typicallyrule-based. An expert system is employed in accordance with the presentinvention by establishing a hardware or software based program whichcontains encoded domain knowledge from a knowledge expert as to therelationship between items of information being sought forclassification—in this case lubricant state. That is, the expert systemcodifies expert knowledge as a rule or set of rules for each decisionand stores given rules and data into the knowledge base. The expertsystem will typically employ an “inference” engine to derivehealth-related knowledge about the subject.

Once the processor 130 has processed all of the respective lubricantdata, the processed data may be sent to the host computer 102 forsubsequent analysis and trending. The host computer 102 may then makedeterminations as to the health of the lubricant based on the datareceived from the lubrication analyzer 90. As will be discussed ingreater detail below in connection with FIG. 4a, the processor 130 mayperform data fusion of the various sensed lubricant or fluid sensedparameter data to facilitate condensing, combining, evaluating andinterpreting the various sensed data. Accordingly, lubricant maintenancecan be scheduled to correspond with the state of the lubricant.Additionally, the processed data can be compiled for trend analysis andforecasting. Since the lubrication analyzer 90 is integrated with themotor 70, the data sampling rate can be substantially high thusproviding for improved highly accurate and up to date data relating tothe health of the lubricant.

However, as mentioned above, it is to be appreciated that lubricantdiagnosis, trend analysis, forecasting, etc. that could be performed bythe host computer 102 may also be performed directly by the lubricationanalyzer 90.

Referring now to FIG. 4a, a data fusion process in accordance with thepresent invention is discussed. A common root cause of machinery failureis lubricant contamination by particles and moisture. In fact, failuresoften attributed to “normal wear” are the result of lubricantcontamination. The inability of the lubricant to perform its intendedfunction can result from high temperature operation or moisture, or theintroduction of debris from the surrounding operating environment orfrom deterioration of internal machine components. Such undesirableoperating condition should be identified quickly and reliably.

Most lubricant/fluid condition management activities fall into one ofthe following three categories: (1) lubricant/fluid health analysis; (2)system conditioning monitoring; and (3) wear or damage analysis. Thefirst two categories relate to the role of the lubricant in providingprotection for the machine components and also as a “local sensor” forsystem health monitoring. Suppliers of lubricants provide detailedtechnical information on the operating characteristics of theirproducts. It is then the responsibility of the user to make sure thatthe lubricant has not degraded to the point where it is ineffective forthe intended application. In this case, it is the condition of thelubricant that is being evaluated. Determining the condition of thelubricant requires inspection of the physical, chemical, and additiveproperties of the lubricant to determine if the lubricant is capable ofperforming its intended function. The lubricant properties that must beevaluated to assess the condition of the lubricating fluid are inherentto the lubricant and should be measurable from any representative sampleof the lubricant.

Although the deterioration of the lubricating qualities of a lubricantcan lead to machine operating problems which can escalate at anexponential rate, a lubricant whose physical, chemical, and additiveproperties are within expected tolerances is not by itself indicative ofa healthy machine. The operating temperature of the lubricant, the levelof contaminants in the lubricant, and the amount of moisture present inthe lubricant are all relevant parameters for assessing the operation ofthe system. The analysis of a lubricant to determine the health of thesystem involves devising an appropriate sampling methodology, includingthe frequency and location of the samples that are to be taken. Thepresent invention provides for a distributed collection of in situmulti-element sensor units, each capable of monitoring lubricantparameters such as temperature and contaminants—including debrisparticles and moisture, and can provide relevant information desirablefor system health monitoring. More particularly, the lubrication sensor20 of the present invention may include a plurality of different sensingdevices such as for example, a temperature detector, pH sensor,viscosity sensor, electro-chemical sensor, electrical conductivitysensor, etc. One, several or all of such sensing devices 26 maybesituated on a single lubrication sensor chip and provide for in situgathering of multiple lubricant parameters. Faults or failures in abearing, for example, are often the result of excessive loading or thedistribution of debris that induces contact between rotating elements.Before the contact can be detected using conventional vibrationanalysis, the cause (e.g., debris) or the effect (e.g., metalparticulates in the lubricant or fluid) are often measurable in thelubricant or fluid. Furthermore, if these and other relevantmeasurements can be obtained within the operating environment of thedevice, e.g., the confines of the bearing, then mechanical faults aswell as degradation in the lubricating fluid can be simultaneouslydiagnosed and localized. Moreover, the analysis may be performed in thecontext of a machinery-rolling element-lubrication system where eachcomponent mutually affects each other component.

The sensor system of the present invention includes sensors(transducers) 26 (FIG. 1) capable of measuring several differentoperating characteristics or parameters of the lubricant within theconfines of the system (e.g., temperature, pH, conductivity, andviscosity (see FIGS. 5a and 5 b)). Signal data from each of thesetransducers 26 is combined within a unified detection and decisionframework to obtain useful information for both the condition of thelubricant and the process employing the lubricant.

An approach to formulate and solve this class of problems is oftenreferred to as data fusion. Data fusion is the process of combininginformation from a set of distributed sensors, each of which isobserving the same or similar/related features of the environment. It iswell understood that the fundamental need for data fusion is because ofthe process of information fission that is inherent to in the process ofsensing a physical environment through several different sensormodalities. Each sensor (S₁−S_(N)) provides a unique window into thephysical environment where the phenomena to be observed is occurring.Because the complete details of the phenomena being studied (e.g.,detecting the operating state of the lubricant or fluid, or the process)are not contained within a single sensor window, there is informationfragmentation or fission. These information fragments which areassociated with the various sensor modalities can contain bothindependent and dependent components. The independent components areused to further fill out (or span) the information space and thedependent components are used in combination to improve the quality ofcommon information because all sensor data is subject to error andnoise. In this context, data fusion is the algorithmic processing ofsensor data to compensate for the inherent fragmentation of informationbecause the phenomena cannot be observed directly using a single sensor.

For example, in the application of multi-element sensor array data todetermine the health of the lubricant or fluid, a combination of sensors(pH, temperature, conductivity, etc.) are employed, each sensor 26providing information related to a particular aspect of the phenomenathat is to be measured. This information is combined and analyzed inorder to make a decision regarding the health of the lubricant or fluid.As sensor modalities are added and a number of multi-element sensorarrays distributed within the operating environment, a data fusionarchitecture provides the correct framework for condensing, combining,evaluating, and interpreting the available information in the context ofthe application.

There are a variety of different approaches to the problem of datafusion. The most common mathematical techniques are based on formulatingthe fusion problem in the context of detection and estimation as astatistical hypothesis testing problem (Neyman-Pearson) or as anoptimization (Markov statistical decision) problem where the costfunctional is either of the Bayesian risk type or of the entropy (mutualinformation) type. Other approaches which use pattern recognition,rule-based methods, and artificial neural networks and/or expert systemsmay be employed.

For the problem of detecting and diagnosing the degradation in thelubricant or fluid and condition-based monitoring of rotating machinery,the mathematical techniques are the most suitable. In this context, thesensed data is used to evaluate the validity of various hypotheses. Forexample, hypothesis H₀ is true if the condition of the lubricant isgood; hypothesis H₁ is true if the operating condition of the rotatingmachine is good, other hypotheses H_(i) where i=2, . . . n are definedaccording to various predetermined fault modes. The objective of thesensor fusion algorithm is to use the data from various sensor elementsto determine which hypothesis (or several) is true (or most likelytrue). A probabilistic framework is most appropriate for computing andanalyzing the various hypotheses. For example, consider a situationwhere a multi-element sensor array incorporates a temperature sensor(y₁), a pH sensor (y₂), and a conductivity sensor (y₃), then the problemof determining if the lubricant or fluid is healthy is equivalent tocomputing the Probability (H₀|y₁, y₂, and y₃) in order to determine theoverall operating state (e.g., health) of the system.

The data fusion architecture shown in FIG. 4a decomposes the computationof Probability (H₀|y₁, y₂, y₃ . . . y_(N)) into individual “local”decisions (U₁, U₂, U₃, . . . U_(N)) and these are combined in a fusioncenter 200 to compute Probability (H₀|y₁, y₂, y₃ . . . y_(N)) and theoverall health of the system. In a decentralized parallel sensorarchitecture as shown in FIG. 4a the centralized fusion center 200 isused to combine the sensor data. Here each sensing device 26 (FIG.1)accepts data (y_(i)) from the environment, locally processes thisinformation and transfers this local information (or decision) (u_(i))to the fusion center 200 for further processing and decision making(U₀).

In the Neyman-Pearson framework, the design of both the local and globaldecision rules to achieve the detection decision U₀ is formulated as aconstrained optimization problem where the objective is to maximize theprobability of detection while constraining the probability of falsealarms. It is well known that under the assumption of conditionalindependence (e.g., the sensed data are statistically independentconditioned on the hypothesis), the optimal local and global decisionrules are of the threshold type in terms of the appropriate likelihoodratio. This is of course, the familiar likelihood ratio test (LRT) forhypothesis testing in a statistical decision theory framework. Since theoptimal decision rule is a positive unate function, for sensorconfigurations such as the present invention, search algorithms like theone illustrated in FIG. 4b may be effectively utilized to find theoptimal decision rules.

Initially, in step 202 the search algorithm sets or fixes theprobability of a false alarm occurring. Next, in step 204, the algorithmselects a monotone decision rule from a set of possible candidates. Forthe rule selected in step 204, the algorithm in step 206 computes“optimal” threshold values that maximize decision probability. Next, instep 208 the probability of detection is computed for the selecteddecision rules. In step 210, the algorithm determines if all monotonedecision rules in a feasible set have been exhausted. If no, thealgorithm returns to step 204 to select another monotone decision rulefrom the feasible set. If yes (all monotone decision rules in thefeasible set have been exhausted), the algorithm proceeds to step 212where the optimal decision rule is determined, which is the decisionrule that has the largest probability of detection.

The following discussion focuses on probabilistic computations tosupport the computation of lubricant health from on-line sensor data.Assume a sequence of sensor measurement, y_(i)[k], where i denotes thesensor index and k denotes the time (sampling) index. Let H_(j) denotethe lubricant health hypothesis that is to be tested, for example,H₀={the lubricant is in good condition, H₁={viscosity of the lubricantis below value xxx}, . . . The basic problem is to computeP_(j)[k]=Prob{H_(j) is true |y_(i)[I], I=0, 1, . . . k}. This can beinterpreted as a decentralized nonlinear filtering problem because it isdesired to build up this computation from decentralized (local)computations based on smaller subsets of the sensor data and updatesequentially in time—hence, the need for data fusion. It is alsopossible to perform a centralized computation.

Data fusion techniques are well-known, and therefore further discussionsrelated thereto are limited for sake of brevity. U.S. Pat. No. 5,661,666entitled Constant False Probability Data Fusion System describes datafusion in substantial detail, and this patent is incorporated herein byreference in its entirety.

Thus, the present invention employs sensor fusion to combine informationfrom two or more sensors in accordance with a pre-established model orframework so as to: (a) improve the accuracy of sensed information; (b)determine the state of a system using the combined sensed information(state estimation); and (c) derive new unmeasurable parameters of thesystem.

With respect to improving accuracy of sensed information, the followingis one specific example. Lubricant conductivity may be measured byemploying two electrodes and measuring resistance. However, the presenceof water in the lubricant will affect the conductivity of the lubricant.If water concentration (p.p.m.) can be measured with another sensor anda certain standard conductivity value for water is assumed, thelubricant conductivity measure may be compensated by the standardconductivity value for water to obtain a more accurate reading of thelubricant conductivity. Alternatively, multiple conductivity sensorswith different probe separation and differing tip to tip potential,respectively, may be combined to provide a more accurate measure ofconductivity by combining these sensed values in an algorithmic manner.

However, in another embodiment a chemical/electro-chemical model may beemployed to determine if a serious lubricant condition exists (excessiveoxidation) or inconsistent condition (e.g., extremely high viscosityunaccounted for or inconsistent with other sensor readings.Alternatively, sensor data may be combined using a model-free estimatorto establish the state of the lubricant. For example, techniques such asunsupervised neural network schemes may be readily employed.

Regarding new parameter derivation, if it is desired to know metalparticulate concentration and particle size (m_(c)), and m_(c) cannot bemeasured directly, an approximate measure for m_(c) may be computed andthis value used in subsequent analysis with other measured (or computedvalues) to determine the health (or operating condition) of thelubricant. In this example, it is known that metal particles act as acatalyst for the oxidation of the lubricant. The rate of oxidation willbe affected by the particulate concentration (among other factors).Other sensed lubricant parameters may also provide evidence of theconcentration of metal particulates such that:

m _(c) =f(o _(r) , c, d, w _(c) , v, f _(v))

where

o_(r)=oxidation rate

c=conductivity

d=dielectric strength

w_(c)=water content

v=viscosity

f_(v)=vibration energy at characteristic frequencies.

A model which incorporates the above measurable quantities is then usedto derive a critical unmeasurable quantity (metal particulateconcentration (m_(c))). This parameter (m_(c)) is a parameter highlyindicative of the health (operating condition) of the lubricant and/orsystem employing the lubricant. There may be no other manner in which toobtain the value for m_(c) in situ, especially for larger sizeparticulates (e.g., 10 μ and higher).

As another example, rather than using an explicit electrochemical modelas above, a neural network 216 (see FIG. 4c) may, be trained to computethe new derived parameter. For example, as in the previous case multiplelubricant samples that span the range of particulate concentration maybe extracted and sampled in a laboratory and direct measurements takenfor all parameters including metal particulate concentration and size.These multiple samples may then be used to train the neural network 216employing a supervised learning scheme such as a feed forward error backpropagation scheme. The neural network derived parameter (m_(c)) maythen be used in subsequent analysis as previously described.

In another embodiment of the present invention, the sensed lubricantparameters may be employed to generate Fourier Transform InfraRed (FTIR)or Attenuated Total Reflectance (ATR) spectra. Laboratory analysis oflubricants may include FTIR or ATR plot(s) to identify the compositionof the lubricant with regard to characteristics such as water content,degree of oxidation, additives present, and contaminants. The presentinvention may be employed to synthesize the FTIR/ATR spectra frommeasured sensed parameters of the lubricant. The intensity values atselect critical frequencies corresponds to the IR absorption of certaincomponents at these frequencies which in turn may be proportional to theconcentration of the specified component. The absorption of the IRenergy is related to the concentration levels according to theBeer-Lambert Law:

A=K·b·C

where

A=absorbency of a sample (at a frequency);

K=absorptivity of the component;

b=unit of thickness;

C=concentration of the component.

The FTIR/ATR intensity values may be generated using regressiontechniques to fit an analytical relationship:

A=f(s₁, s₂, s₃, . . . s_(n))

where the absorption at a particular frequency is a function of “n”sensed parameters—“n” being an integer. Alternatively, A, the absorptionintensity at critical frequencies could be generated using theaforementioned neural network technique with supervised learning.

Another embodiment of the present invention may provide for synthesizing(such as with the neural network 216) a new parameter which may directlyindicate the health (operating condition) of the lubricant or fluid. Forexample, the present invention may be employed to synthesize the ratioof sulfates plus carboxyls divided by water content. Such a parametermay indicate the likelihood of the lubricant to begin corroding abearing surface, for example.

Turning now to FIG. 4d, a schematic block diagram of a data fusionsystem 220 in accordance with one embodiment of the present invention isshown. The data fusion system 220 includes a multi-device sensing system222, which includes a plurality of sensing devices (1-N). Each sensingdevice provides for sensing various parameters of a lubricant or fluidbeing analyzed. The sensed parameters from the sensing devices of themulti-device sensing system 222 are input into an analog to digitalconversion system 224 which converts the analog values from the varioussensing devices into digital form for processing by a data fusionprocessor 226. The data fusion processor 226 employs a data fusionframework on the digitized sensed parameters in the manner describedabove to provide for facilitating condensing, combining, evaluating andinterpreting the various sensed data in order to facilitate rendering ahealth (operating condition) assessment of the lubricant or fluid beinganalyzed.

FIG. 4e is another embodiment of the present invention similar to theembodiment of FIG. 4d. Like components between FIG. 4d and FIG. 4einclude like reference numerals except that the reference numerals ofFIG. 4e are also followed by a prime (′). In this embodiment, thesensing devices 222′, the analog to digital conversion system 224′ andthe data fusion processor 226′ are all integrated onto a singlesemiconductor surface 230.

Each sensing device of FIGS. 4d and 4 e may comprise a pH sensor or atemperature sensor or a electrical conductivity sensor or a viscositysensor or a chemical sensor, or a combination thereof. Thus, somesensing devices may be only a single parameter sensor while othersensing devices may be a complete lubrication sensor (including aplurality of sensors for sensing different parameters).

FIG. 5a illustrates yet another embodiment of the present invention. Inthis embodiment a multi-element sensor 250 is provided which includes apH sensor 260, an electrochemical sensor 264, a electrical conductivitysensor 268, a temperature sensor 274, and a viscosity sensor 278. The pHsensor 260, the electrochemical sensor 264, the conductivity sensor 268,and the temperature sensor 274 are essentially the same as thatdescribed in connection with FIG. 1 and therefore further discussionrelated thereto is omitted for sake of brevity. The viscosity sensor 278provides for sensing the viscosity of the lubricant or fluid beinganalyzed. In short, the viscosity sensor 278 works in conjunction withthe temperature sensor 274 to facilitate analyzing the viscosity of thelubricant or fluid being analyzed.

The viscosity sensor 278 includes a plurality (e.g., array) offinger-like elements (e.g., cilia) 280 which are plated with anelectrically conductive material. The finger-like elements 280 extendperpendicularly from a surface 284 of the sensor, and the sensor 278functions based on the phenomena that a dissipative or damping forcethat resists the motion of the energized finger-like elements 280results in an increased power demand to maintain oscillation of thefinger-like elements 280 at a particular frequency. A lubricant or fluidof high viscosity will exert a greater damping force on the oscillatingfinger-like elements 280 than a lubricant of lower viscosity. As aresult, more power is required to maintain oscillation of thefinger-like elements 280 at a particular frequency in a high viscositylubricant or fluid than a lubricant or fluid of lower viscosity. Thus,the viscosity of a lubricant or fluid may be determined via the microviscosity sensor 278 of the present invention by monitoring the powerrequired to oscillate the finger-like elements 280 at a particularfrequency and/or range of frequencies. Since the viscosity of alubricant or fluid is also a function of lubricant or fluid temperature(e.g., typically, the higher the lubricant or fluid temperature thelower the lubricant or fluid viscosity), the present invention alsoemploys the temperature detector 274 to correlate the temperature of thelubricant or fluid with the aforementioned power requirements toaccurately interpret lubricant or fluid viscosity. A more detaileddiscussion relating to the operation and fabrication of such a viscositysensor is found in U.S. patent application Ser. No. 09/054,117, entitledMICRO-VISCOSITY SENSOR AND LUBRICATION ANALYSIS SYSTEM EMPLOYING THESAME, which as mentioned above is hereby incorporated by reference inits entirety.

FIG. 5b illustrates another embodiment of the present invention similarto the embodiment of FIG. 5a. Like components between FIG. 5a and FIG.5b include like reference numerals except that the reference numerals ofFIG. 5b are also followed by a prime (′). In this embodiment, themulti-element sensing system 250′ also includes a processor 290integrated on the semiconductor surface 284′. The processor 290 providesfor carrying out the general operations of the system 250′ includingdata fusion in accordance with the data fusion framework describedabove. The processor 290 can be any of a plurality of suitableprocessors, such as for example: CPU die or processor/logic/storagebonded (flip chip) to the sensor substrate—the sensor elements may bewire bonded to processor I/O connection points. The manner in which theprocessor 290 can be programmed to carry out the functions relating tothe present invention will be readily apparent to those having ordinaryskill in the art based on the description provided herein and thusfurther discussion related thereto is omitted for sake of brevity.

Thus, this embodiment provides for a substantially autonomous lubricantanalysis system. The system 250′ may provide for performing lubeanalyzer functions as well as affording for self diagnosis. The system250′ may also be able to verify that it is in a feasible operatingregime.

Turning now to FIG. 6a, a lubricant analysis system 350 in accordancewith an embodiment of the present invention is shown. In thisembodiment, it is desired to monitor the state of a lubricant 356employed to lubricate a motor bearing 358. As shown, a multi-elementsensor 360 (FIGS. 1, 5 a, 5 b) is located proximate to the motor bearing358 and is in contact with the bearing lubricant 356. The multi-elementsensor 360 is also operatively coupled to a lubricant analyzer 370 whichreceives and processes data gathered by the multi-element sensor 360 inthe manner described above. The lubricant analyzer 370 includes a datafusion system 372 for performing the data fusion of sensed parameters inaccordance with the present invention.

In many motor designs, and particularly in motor designs utilizingspherical or self-aligning bearings, the use of unsuitable lubrication(degraded, contaminated, etc.) prevents maintaining a suitablelubrication film between the bearing and the bearing raceway so as tominimize wear and heating of the bearing. In turn, this inadequatelubrication oftentimes results in excessive friction, wear, and heat,which in turn may cause premature failure of the bearing thus possiblyresulting in detrimental effects on the health and efficiency of themotor.

The present invention affords for monitoring the health of the bearinglubricant in a precise, reliable, inexpensive, convenient andsubstantially continuous manner. The lubricant analysis system 350provides for frequently monitoring the health state of the lubricant356, and can provide for scheduled maintenance of the lubricant 356 inorder to facilitate maximizing the life and efficiency of the motorbearing 358 and minimizing maintenance cost.

It is to be appreciated that the present invention has numerousapplications (e.g., forced lubrication systems; gear boxes; hydrodynamicbearings and other bearing systems, oils, grease, hydraulic fluids,cutting oils and other types of fluids where measured and derivedknowledge thereof is desired). Each such fluid is susceptible toproblems and exhibit symptoms with viscosity and temperature asdescribed here (e.g. contamination, breakdown). All such applicationsare intended to fall within the scope of the present invention asdefined in the claims.

FIG. 6b illustrates another aspect of the present invention wherein thelubricant analyzer 370 is coupled to two different multi-element sensors360 _(a) and 360 _(b). Multi-element sensor 360 _(a) is coupled to aload end bearing 358 _(a), and multi-element sensor 360 _(b) is coupledto a fan end bearing 358 _(b). The lubricant analyzer 370 will monitorthe health states of lubricants 356 _(a) and 356 _(b) for eachrespective bearing.

It is to be appreciated that a plurality of multi-element sensors (360 ₁thru 360 _(n)) may be coupled to a single lubricant analyzer 370 asshown in FIG. 6c. Thus, the health state of lubricants of severaldifferent pieces of equipment (e.g., motors, gear box, pillow block,pump) may be monitored by the single lubricant analyzer 370.

FIGS. 7a-7 f illustrate various environments in which the multi-elementsensor 20, 250, 250′ of the present invention may be employed. It is tobe appreciated that these environments are only some exampleenvironments of many and that the present invention is not intended tobe limited to only the environments described herein.

FIG. 7a is a schematic block diagram illustrating the multi-elementsensing device 20, 250, 250′ being employed in connection with analyzinglubricant or fluid used in a gear box 400.

FIG. 7b is a schematic block diagram illustrating the multi-elementsensing device 20, 250, 250′ being employed in connection with analyzinglubricant or fluid used in a bearing set in a pillow block 402.

FIG. 7c is a schematic block diagram illustrating the multi-elementsensing device 20, 250, 250′ being employed in connection with analyzinglubricant or fluid used in a hydrodynamic bearing 404 housed in housing406.

FIG. 7d is a schematic block diagram illustrating several multi-elementsensing devices 20, 250, 250′ being employed in connection with a pumpsystem 410, wherein one sensing device senses parameters relating tofluid or lubricant exiting the pump and the other sensing device sensesparameters relating to fluid or lubricant entering the pump.

FIG. 7e is a schematic block diagram illustrating several multi-elementsensing devices 20, 250, 250′ being employed in connection with abearing 420, wherein the sensing devices are suitably positioned alongthe bearing raceway to sense parameters relating to lubrication of thebearings.

FIG. 7f is a schematic diagram illustrating a couple of multi-elementsensing devices 20, 250, 250′ being employed in connection with aprocess 430, wherein one sensing device senses parameters relating tofluid exiting a machine and the other sensing device senses parametersrelating to fluid exiting a filter.

Turning now to FIGS. 8-15, an illustrative batch fabrication methodologyfor the lubricant sensor 20 of FIG. 1 is provided. Referring now to FIG.8 in particular, the process begins with a substrate layer 500 ofsemiconductor material such as silicon for example, but it is to beappreciated that any suitable material for carrying out the presentinvention may be employed. A plurality of different masking steps areperformed on the substrate 500 to deposit the different metals which areemployed in forming the various sensors 26.

An initial patterning step 502 is performed to form the pH electrode 30wherein standard photolithographic and deposition techniques are carriedout to form the palladium pH electrode 52 shown in FIG. 9. Next as shownin FIG. 10, another photo lithographic/deposition step is performed toform the gold conductivity sensors 58, and the gold counter electrode 56and the gold working electrode 54 of the electrochemical sensor 36 asseen in FIG. 11. FIG. 12 illustrates a third photolithographic/deposition step 506 wherein a lift-off procedure isperformed to apply platinum as is well known in the art. Platinum isdifficult metal to etch and thus a lift-off procedure is preferred whenworking with platinum. This substantially completes the fabrication ofthe lubricant sensor 20 shown as shown in FIG. 1.

Although the present invention has been described primarily in thecontext of a preferred embodiment, it is to be appreciated that thepresent invention may be carried out in other embodiments. For instance,both top and bottom sides of the base 24 (FIG. 1) may includetransducers 26 as compared to only a single side of the base 24. Such anembodiment enhances the functional scope of the present invention bydoubling the amount of sensitive components of the lubricant sensor.

Although, the present invention has been described with respect tosensing and analysis of a lubricant, it is to be appreciated that thepresent invention provides for in situ monitoring, health assessment andfuture lube requirements assessment of any suitable fluid whereknowledge thereof is desired.

What has been described above are preferred embodiments of the presentinvention. It is, of course, not possible to describe every conceivablecombination of components or methodologies for purposes of describingthe present invention, but one of ordinary skill in the art willrecognize that many further combinations and permutations of the presentinvention are possible. Accordingly, the present invention is intendedto embrace all such alterations, modifications and variations that fallwithin the spirit and scope of the appended claims.

What is claimed is:
 1. A multi-element fluid sensor system, comprising:at least two sensors, each sensor adapted to collect data relating to afluid; and a data fusion processor operatively coupled to the at leasttwo sensors, the data fusion processor processing the fluid data to atleast compensate for fragmentation of information attributed to usingthe at least two sensors.
 2. The system of claim 1, the at least twosensors being integrated onto a semiconductor base.
 3. The system ofclaim 1, the data fusion processor condensing the fluid data.
 4. Thesystem of claim 1, the data fusion processor combining the fluid data.5. The system of claim 1, the data fusion processor evaluating the fluiddata.
 6. The system of claim 1, the data fusion processor interpretingthe fluid data.
 7. The system of claim 1, the at least two sensorsincluding a pH sensor.
 8. The system of claim 1, the at least twosensors including a chemical sensor.
 9. The system of claim 1, the atleast two sensors including a conductivity sensor.
 10. The system ofclaim 1, the at least two sensors including a temperature sensor. 11.The system of claim 1, the at least two sensors including a viscositysensor.
 12. The system of claim 1 providing for in situ monitoring ofthe fluid.
 13. The system of claim 1, the fluid is one of: oil, grease,hydraulic fluid, cutting oil/cutting coolant, and biological fluid. 14.The system of claim 1 wherein the fluid is employed to lubricate atleast one bearing of a dynamoelectric machine.
 15. The system of claim 1used in a forced lube system.
 16. The system of claim 1 used in a gearbox.
 17. The system of claim 1 used in connection with hydrodynamicbearings.
 18. The system of claim 1 used in connection with a bearingsystem.
 19. A fluid sensing system, comprising: at least a distributedset of two sensors integrated onto a semiconductor, base, the sensorsrespectively collecting data relating to a fluid; and a data fusionprocessor also integrated onto the semiconductor base and beingoperatively coupled to the at least two sensors, the data fusionprocessor processing the fluid data to at least compensate forfragmentation and overlap of the fluid data attributed to using the atleast two sensors.
 20. The system of claim 19 used to provide in situmonitoring of the fluid.
 21. The system of claim 19, the data fusionprocessor condensing the fluid data.
 22. The system of claim 19, thedata fusion processor combining the fluid data.
 23. The system of claim19, the data fusion processor evaluating the fluid data.
 24. The systemof claim 19, the data fusion processor interpreting the fluid data. 25.The system of claim 19 the at least two sensors including a pH sensor.26. The system of claim 19 the at least two sensors including a chemicalsensor.
 27. The system of claim 19 the at least two sensors including aconductivity sensor.
 28. The system of claim 19 the at least two sensorsincluding a temperature sensor.
 29. The system of claim 19 the at leasttwo sensors including a viscosity sensor.
 30. A distributed sensorsystem for in situ monitoring of a lubricant employed in adynamoelectric machine, comprising: a plural sensor means for collectingdata for a plurality of parameters relating to the health of thelubricant; and an algorithmic processing means for fusing the data to atleast compensate for fragmentation and overlap of information betweenthe data for the plurality of parameters.
 31. A distributed sensormethod for in situ monitoring a lubricant, in terms of any data,information or parameter that corresponds to a health state or qualitylevel for said lubricant comprising the steps of: using a distributedset of at least two sensors to collect a sum of data relating to thehealth state of the lubricant while the lubricant is being used; andusing a data via an algorithm implementation to at least compensate forany information fragmentation or fusion fusion system to process thedata.
 32. A lubrication sensor for assessing a quality, condition orhealth state in a lubrication application comprising: a distributed setof at least two sensors, each sensor adapted to collect data relating toa lubricant; and a data fusion processor operatively coupled to the atleast two sensors, the data fusion processor processing the lubricantdata via an algorithm implementation to at least compensate forfragmentation and/or overlap of information attributed to using the atleast two sensors.
 33. A lubrication sensor for use in connection with adynamoelectric machine, comprising: a set of distributed sensorsincluding at least two of the following sensing devices adapted tocollect data relating to a lubricant: a temperature sensor for sensingtemperature of the lubricant; a viscosity sensor for sensing viscosityof the lubricant; a chemical sensor for sensing chemical parameters ofthe lubricant; a conductivity sensor for sensing electrical conductivityof the lubricant; a pressure sensor for sensing lubricant pressure; ashear viscosity sensor for sensing lubricant shear; and a density sensorfor sensing lubricant density; and a pH sensor for sensing lubricant pH;and a data fusion processor operatively coupled to the at least twosensing devices, the data fusion processor processing the lubricant datavia an algorithm implementation to at least compensate for fragmentationand/or overlap of information attributed to using the at least twosensing devices.
 34. A multi-element fluid sensor system having adistributed sensor configuration comprising: a first sensor adapted tocollect data relating to a fluid; a second sensor substantiallyidentical to the first sensor, the second sensor providing redundancy incollecting the fluid data via an algorithm implementation to at leastcompensate for any information fragmentation or fusion; and a datafusion processor operatively coupled to the first and second sensors,the data fusion processor processing the fluid data; wherein theemployment of the second sensor facilitates fluid data reliability andaccuracy.